AA - SPEC - 114005 - Flooring, Stairs, Ladders & Handrails

AA SPECIFICATION 114005
STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

AND GUARDRAILS COPYRIGHT
CONTENTS PAGE
1 SCOPE 2
2 TECHNICAL REQUIREMENTS 2
2.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2
3 DEFINITIONS 2
4 GENERAL REQUIREMENTS 5
4.1 SAFETY AND RISK 5
4.2 GENERAL REQUIREMENTS 6
4.3 REQUIREMENTS FOR DESIGN 7
4.4 REQUIREMENTS FOR FABRICATION AND SUPPLY 20
4.5 REQUIREMENTS FOR INSTALLATION 25
4.6 REQUIREMENTS FOR USE 30
4.7 REQUIREMENTS FOR MAINTENANCE AND REPAIR 36
5 QUALITY ASSURANCE PROVISIONS 41
5.1 QUALITY MANAGEMENT 41
5.2 QUALITY PLAN 41
5.3 TEST FACILITIES 42
5.4 INSPECTION 42
APPENDIX A: RELATED DOCUMENTS 43
APPENDIX B: RECORD OF AMENDMENTS 44
APPENDIX C: APPROPRIATE NATIONAL STANDARDS 45
AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 1 of 45
For information or comments on this document please contact AT R&A

Anglo Technical accepts no liability for any damage whatsoever that may result from the use of this material or the information
contained therein, irrespective of the cause and quantum thereof.

This document supersedes AAC Specification 114005 Rev 5
1 SCOPE
This specification details the Anglo American plc minimum requirements for the design,
supply, fabrication, installation, use and maintenance of steel and FRP flooring and
walkways, stairs and guardrails. Steel flooring includes open grid flooring, expanded
metal flooring and vastrap plate flooring.
This specification is intended for use with flooring, stairs, ladders and guardrails on steel
framed structures on surface and underground, in processing plants, materials handling
systems, heavy mobile machinery and mine shaft structures. All areas under the
management of AA or any of its operating divisions are included.
This specification should be read in conjunction with AA BPG S006 “Guidelines for Layout
and Inspection of Steel and FRP Floors, Stairs and Guardrails”.
This specification shall also be read in conjunction with any applicable requirements of
local legislation and standards. The more stringent of this specification and local
requirements shall apply. In particular, in Australia the draft standard DR01136 “Fixed
Platforms, Walkways, Stairways and Ladders – Design, Construction and Installation”
shall be read in conjunction with this specification.
2 TECHNICAL REQUIREMENTS
2.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

For all new work the Project Engineer, and for all repair or replacement work the Mine
Engineer, shall specify the following requirements on all invitations to tender, contracts or
orders:
• Number, title, date and issue of this specification
• Number, title and issue of the relevant drawings
• Type of material to be used in the manufacturing of flooring, stairways and handrails
• Corrosion protection requirements
• Fire rating and fire protection requirements
• Panel fastening methods
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:
AT : Anglo Technical
BANDING : A bar of equal depth and thickness to the bearer bars which
is welded to the grating around the outer ends and edges of
the panel.


BEARER BAR : The load carrying component of walkway grating running

between structural supports.
Note: This may also be referred to as a load-bearing bar, a carrier bar, or a
span bar.
BS : British Standard
DESIGN DRAWINGS : As defined by AA SPEC 114001
DESIGN ENGINEER : As defined by AA SPEC 114001
DESIGNATED : A Foreman who is appointed in writing by the Mine
FOREMAN Engineer as having responsibility for steel and FRP flooring,
stairs and guardrails. The Designated Foreman should
have specific training and experience in the use and
inspection of steel and FRP flooring, stairs, ladders and
guardrails
DLS : The appropriate national standard for limit states structural

design of mine shafts
FRP : Fibre Reinforced Polymer. The fibre used is usually glass

but may also be carbon or other materials. A variety of
polymers is used, depending on the requirements of the
specific application
GRADED : Materials supplied to a guaranteed strength and having a
fully traceable origin
GUARDRAIL : A fixed safety handrail system, or barrier, around working
areas or floor areas. It consists of a hand rail, a middle rail
and a toeboard at the floor level.
GWS : The appropriate national standard defining the chemical

and mechanical properties of weldable structural steels
LENGTH OF PANEL : Overall dimension of a grating panel measured parallel to the

bearer bars.
LOAD BEARING : A toeboard designed to carry loads from flooring which is not
TOEBOARD directly supported on beams.
LSD : The appropriate national standard for limit states design of

structural steel
MINE ENGINEER : The Engineering Manager of the Purchaser, or a person

appointed in writing by the Engineering Manager to take
responsibility for the particular area of the mine.
NOSING : A special non-slip edging attached to, or formed along, the
front edge of a stair tread or landing edge.
Note: This may also be referred to as the sighting edge.


PITCH : The distance centre to centre of bearer bars or centre to

centre of transverse bars.
PROJECT ENGINEER : The company appointed by the Purchaser to be responsible
for the management of the project.
PURCHASER : The mine company that places the order and receives the
goods.
: Quality Assurance Representative. An independent
QAR
inspection agency appointed by the Purchaser.
SANS : South African National Standards
: A flat plate welded to the ends of a stair tread and drilled for
SIDE PLATE
bolting to the stair stringer.
SLO : The appropriate national standard for structural loading
SS : Stainless steel
SSC : The appropriate national standard for structural steel

construction
STAIR TREAD : A rectangular pattern bar grating with a non-slip nosing.

: A stair stringer or ladder stringer is the structural side
STRINGER
member of the stair or ladder.
STS : The appropriate national standard for stainless steel

sections
: A company that manufactures and supplies walkway grating,

SUPPLIER
guardrail and/or stair components.
: A flat bar welded to the end or side of a floor panel,
TOEBOARD projecting at least 100mm minimum above the grating.
Note: This may also be referred to as a kick plate.
: Member at right angles to the bearer bars to provide lateral

TRANSVERSE BAR
restraint.
: Overall dimension of a grating panel measured at right
WIDTH OF PANELS
angles to the bearer bars.
The following terms are defined in the General Conditions of Contract:

• Anglo American, Approved, Company, Contractor, Engineer


4 GENERAL REQUIREMENTS
4.1 SAFETY AND RISK

4.1.1 Anglo Fatal risk Standards
All work on new installations, maintenance or repair of steel and FRP floors and
walkways, stairs, ladders and guardrails shall take cognisance of the Anglo Fatal Risk
Standards, in particular the standard AA AFRS 07 “Working at Heights”.
4.1.2 Risk Assessment

• New Installations
The Project Engineer shall ensure that the Mine Engineer, the Project Engineer and
the Design Engineer conduct a risk assessment and generally work in compliance
with AA STD 99 “Risk Management on Projects” for all new installations prior to any
work being carried out.
• Existing Installations
The Mine Engineer shall conduct a risk assessment and generally work in
compliance with AA STD 99 “Risk Management on Projects” for all existing plant
installations prior to any maintenance or operations activity that affects the steel and
FRP floors and walkways, stairs, ladders or guardrails.
• Minimum Requirements
The risk assessment shall consider at least the following:
1. Installation
The installation of all flooring and stairs shall be considered under the risks
associated with working at heights, because there is no working surface in
place. The installation of guardrails shall also be considered under the risks
associated with working at heights, because the work takes place at
unprotected edges.
2. Fire
Many of the FRP products are “fire retardant”. This means that they will not
burn if removed from a fire source. However, if subjected to a significant fire
for any length of time the resins deteriorate completely, so that they become
unsafe to use as flooring. When considering the use of FRP products the
speed of emergency evacuation and access for fire-fighting personnel should
be carefully considered.
3. Access and Escape

Walkways and stairs are often an integral part of emergency escape routes.
All walkways and stairs designated as escape routes shall be sufficiently wide,
and be kept clear of obstructions, so as to allow free movement of people.
Dedicated green coloured plates in steel or fire retardant FRP may be used to
demarcate these escape routes.


Where ladders are installed, it is particularly important that this is taken into
account, as they provide only limited and slow movement of people.
Open grid floors allow escaping gases or flames from a fire below to pass
through the openings. Solid plates below emergency escape routes can
deflect flames or gases and provide safer egress for people in the event of an
emergency.
4. Falling objects
Where open grid steel of FRP grating is used, it is possible for small objects
to fall through the grating. Objects may also fall through whatever cutouts are
formed in the flooring. Spillage may also pass through open grid flooring and
accumulate below. The risk assessment should include consideration of any
risks to workers or equipment below the floor due to falling objects or
accumulation of spillage.
5. Ventilation
Open grid flooring allows free movement of dust, air and gases. This allows
escape of noxious and explosive gases which may be present in certain areas
of plants. This may be desirable or undesirable under different conditions, so
it should be considered within the risk assessment.
4.2 GENERAL REQUIREMENTS

4.2.1 Compliance with Legislation and AA Requirements
All material and services shall comply with the mandatory requirements of applicable
legislation, relevant to the country and jurisdiction in which the mine site is located. The
Contractor shall confirm this compliance in writing to the Purchaser.
All work done on installation, maintenance and repair of steel and FRP flooring and
walkways, stairs and guardrails shall be done in compliance with the Anglo Fatal Risk
Standard (AA AFRS 07) “Working at Heights”.
4.2.2 Deviation from this Specification
Any proposed deviation from this Specification and its requirements, or modifications for
application to specific items proposed by the Supplier, shall be submitted to the
Engineering Manager: Structures of Anglo Technical for written approval.
4.2.3 Meaning and Precedence of Information
If any doubt arises as to the meaning or effect of any part of this Specification or if conflict
occurs between this Specification and other information it shall be referred to the
Engineering Manager: Structures of Anglo Technical Division for a ruling. The decision of
the Engineering Manager: Structures shall be final.
In the event of any conflict between the technical requirements of relevant documents, the
order of precedence shall be:
• This specification


• The data sheets and/or drawings

• Other relevant documents
4.3 REQUIREMENTS FOR DESIGN

4.3.1 General
The design shall comply with the requirements of AA SPEC 114001, as amended by this
specification.
4.3.2 Alternative Designs
This specification defines the minimum prescribed standards. Alternative designs that
represent an improved or equivalent standard may be proposed and presented to the
Engineering Manager: Structures of AT for approval. Alternative designs may only be
used after they have been approved in writing.
4.3.3 Materials
All materials used shall comply with the requirements below. All materials shall be clearly
specified on the Design Drawings.
• Condition of Material
All material shall be new.
Pitting or rusting of steel surfaces shall not be more severe than grade C of
ISO 8501 unless otherwise agreed by the Design Engineer.
• Structural Carbon Steel
1. Steel sections
All materials shall be graded hot formed steel, complying with the relevant GWS,
with guaranteed yield strength not less than 350MPa. No commercial quality or
ungraded steel shall be used.
Surface defects shall not exceed the extent allowed by the relevant GWS.
2. Bolts
Steel bolts for use in structural bolt connections shall comply with the requirements
of AA SPEC 114001.
Bolts for attachment of stair treads and guardrail standards shall have a diameter of
not less than 16mm and shall be graded high strength structural bolts.
Bolts for clips and attachment of flooring and toeboards shall have a diameter of not
less than 8mm and shall be graded standard strength structural bolts.
• Stainless Steel
1. Material


General stainless steel materials used for flooring, stairs, ladders and guardrails
shall:
Be either Grade 304 or Grade 316
Have a guaranteed minimum yield stress in the annealed condition of not less
than 200MPa
Have a guaranteed minimum yield stress, achieved by cold working before
manufacture, of not less than 220MPa and not more than half the minimum
tensile strength
2. General sections, tubes and plate
All materials shall comply with the following specifications, whichever is applicable:
Stainless steel tubing, plate and strip shall conform to the requirements of the
relevant STS.
3. Fasteners
The dimensions of stainless steel fasteners shall comply with an approved national
or international standard.
4. Surface finish
Stainless steel surface finishes shall not be less than a 2D finish.

• 3CR12
All materials shall comply with the following specifications, whichever is applicable:
AA SPEC 114002 – Appendix B (3CR12)

• Welding Consumables
Welding consumables shall produce weld metal, which when tested in accordance
with the applicable method given in AWS D1.1, has a minimum yield stress and
minimum tensile strength at least equal to that of the parent metal.
• FRP
5. Construction
Grating should be of a moulded construction with the roving of the bearing bars and
transverse bars interwoven to ensure maximum strength of construction.
The resin rich outer surface of the grating shall be a minimum of 0.25mm thick
Any drilled hole or cutting area shall be resin sealed to a minimum thickness of
0.25mm.
6. Resin Content and Ultraviolet Absorber
FRP grating shall be constructed by thoroughly wetting out fibreglass roving with a
suitable synthetic resin, and shall have a resin content of between 60 - 70%.


All grating shall be manufactured with an ultraviolet absorber.
7. Fire Resistance
All grating shall be fire retardant, and shall be non-combustible at a temperature of

not less than 750°C.
All grating shall maintain its full strength for a period of not less than 2 hours in a
fire with a temperature following the standard time temperature curve as defined in
ISO 834.
8. Approval
The Mine Engineer shall approve the proposed resin system before use.
• Specific Material and Corrosion Protection Applications
The specific materials and corrosion protection systems listed in Table 4.1 shall be
used in different areas of plants and mines.
TABLE 4.1: SPECIFIC MATERIALS

Hand rails.
Floor grating
Description Knee rails.
Stair treads
Stanchions.
1. General dry areas.
2. Crushing and screening.

Structural carbon steel hot
Structural carbon steel.
3. Conveyor gantries. dip galvanised or painted
Hollow sections to be hot dip
in accordance with
galvanised.
4. Headgears. CPS 000124.
5. Well ventilated, dry

underground areas.
1. Wet plant area with no Structural carbon steel hot Structural carbon steel hot
acid present. dip galvanised. dip galvanised.
1. Poorly ventilated or wet Structural carbon steel hot Structural carbon steel hot
underground areas dip galvanised. dip galvanised or 3CR12.
1. High temperature furnace Structural carbon steel hot

Structural carbon steel.
area. dip galvanised.
Structural carbon steel

1. Converter area Structural carbon steel. glass flake/epoxy
(dipped).
1. Flash drier area 304 SS 304 SS or 3CR12


Hand rails.
Floor grating
Description Knee rails.
Stair treads
Stanchions.
1. Wet or dry areas where

sulphurous (SO3/SO2) 304 SS or 316 SS 304 SS or 316 SS
fumes or dust is present.
1. Areas where sulphuric

304 or 316 SS FRP
acid (H2SO4) is present.
1. Wet or dry plant areas FRP or structural carbon

where chloride liquid, FRP sections or 3CR12 steel glass flake/epoxy
fumes or dust is present. (dipped).
Note: Where no paint or other corrosion protection system is specified for structural carbon steel, the
same paint system as used for the surrounding structural steelwork shall be used.
Painting and protective coating shall be in accordance with AA CPS 000124.
Hot dip galvanising shall be in accordance with ISO 1461. For particularly corrosive
environments it is recommended that the flooring panels be hot dip galvanised to
ISO 1461 followed by hot dipping in black bitumen in accordance with an agreed
procedure.
Nuts, bolts, washers and screw threads shall be protected with a suitable corrosion
inhibitor.
Where a glass flake/epoxy coating is required, this shall be a coating approved for
use in a chloride environment (for example “Vitaglass/VPB747-ST”). The grating
and stair treads shall be coated by dipping to a thickness of 150 to 300 microns.
Hand rails and guardrail standards can be hand painted or spray painted to a
thickness of 150 to 300 microns. Anglo Technical shall approve the coating system
before use.
4.3.4 Loads
• General
The minimum imposed floor and stair loads defined by SLO, as modified and
supplemented by the AA SPEC 114001, shall be used for surface structures and
general underground structures.
The minimum imposed floor load defined by DLS shall be used for shaft structures.
• Storage and Maintenance Loads
Where it is intended that any spares or equipment are to be stored on steel or FRP
flooring, or placed on steel or FRP flooring during maintenance, the steel or FRP
flooring and its supports shall be specifically designed for this purpose. Any area
designed for storage purposes or load carrying during maintenance shall be
specifically and clearly marked with the design load.


4.3.5 Design Drawings
Design drawings shall comply with the requirements of AA SPEC 114001
In addition, the design drawings shall provide the following information:

• The span direction of all floor grating
• The size and location of any load bearing toeboards
• All cut-outs greater than 150mm x 80mm
• Guardrail locations, section sizes, material and maximum standard spacing
4.3.6 Layout of Floor Grating

• Modular Design
The components shall be designed in such a manner as to facilitate modular

manufacture.
• Type of Grating
Open grid grating made of steel or FRP may be used in any appropriate application.
Expanded metal grating shall not be used, except on access walkways, where the
walkway width does not exceed 750mm and the applied load does not exceed
2.5kPa.
• Span of Grating
Walkway grating shall be supported along both ends. The maximum span of
walkway grating shall be based on the Supplier’s recommendations, usually
contained in a table in their catalogues. The Supplier’s recommended maximum
safe span shall not be exceeded.
Walkway grating panels may extend over more than one span, up to a maximum of
three spans, to improve load distribution and deflection performance.
Where it is necessary to cantilever grating, the length of the cantilever shall not
exceed 10% of the tieback length or 100mm, whichever is the lesser. The Design
Engineer shall provide design calculations demonstrating the adequacy of the
selected grating strength for this cantilever portion, taking cognizance of possible
buckling of the bearer bars.
• Seating of Grating
The seating of grating on supporting steelwork shall not be less than 50mm. Where
a beam supports two adjacent floor grating panels but its flange is less than 100mm
wide, a detail shall be derived to ensure compliance with this requirement. In the
case of panels supported on channels, a ledge seating angle may be necessary.
The entire width of both ends of all steel floor grating panels shall be supported on
beams, except that small openings are permitted where the size of the opening
does not exceed:


Openings not exceeding 100mm long and 50mm wide. These openings shall
have banding around the edges of the opening.
Openings not exceeding 500mm long and 100mm wide. These openings
shall have load bearing toeboards around the edges of the opening.
Gap in the support beam not exceeding 1000mm in width, or half the width of
the panel. The steel floor grating panels over these gaps shall have a load
bearing toeboard along the edge.
The entire width of both ends of all FRP floor grating panels shall be supported on
beams, except that small gaps not exceeding 100mm in width are permitted in the
beams, provided that there is not more than one gap along any one side of a panel.
• Floor Panel Clearance
To facilitate erection, clearances shall be allowed around floor grating panels as

follows:
10.0mm between adjacent floor panel sections
10.0mm between the edge of the flooring panel and any adjacent structure
Toeboards
1. General
Toeboards shall not be less than 130mm high x 8mm thick.
Toeboards shall be provided at all open edges of flooring including stair wells and
equipment openings.
Toeboards shall project a minimum height of 100mm above the flooring.
2. Load bearing toeboards
Load bearing toeboards shall only be used where all of the following conditions are
met:
A straight load bearing toeboard shall not exceed 1000mm in width.
A cranked load bearing toeboard shall not exceed 500mm in width by 100mm
offset.
No more than one section of load bearing toeboard shall be used on any one
flooring panel.
The load bearing toeboard shall have a ratio of depth to thickness which does
not exceed 200/√fy, where fy is the yield strength of the steel used.
The Design Engineer shall provide design calculations demonstrating the adequacy
of load bearing toeboards.
• Bar Spacing and Size
1. Steel floors
Bearer bar centres shall not exceed 50mm


Transverse bar centres shall not exceed 100mm

The depth of bearer bars shall not be less than 30mm
The thickness of bearer bars shall not be less than 4.5mm
The diameter of transverse bars shall not be less than 8.0mm
2. FRP floors
Bearer bars and transverse bars are typically the same size
Bearer bar centres shall not exceed 40mm
Transverse bar centres shall not exceed 100mm
The depth of bars shall not be less than 30mm
The thickness of bars shall not be less than 4.5mm
• Walking surfaces to be Non-Slip
All grating shall have a non-slip walking surface, preferably utilizing either serrated
or pinched bearer-bar profiles for steel grating and meniscus top for FRP grating.
All stair treads shall be equipped standard with fabricated non-slip nosing.
The Purchaser shall approve the non-slip finishes at tender stage.

• Inclined Walkways
The slope of inclined walkways, along conveyor gantries or where inclination of the
walkway is required for any reason shall not exceed 20°. Where the inclination
exceeds 10°, square bars shall be fixed across the surface or some other means
shall be used in addition to the non-slip surface to prevent slipping.
On all inclined walkways specific positive provision shall be made to permanently

secure panels against sliding down the walkway.
• Lateral Location of Grating
All grating shall where possible be designed to be located between guardrail

standards or toeboards or seated into a recess to prevent lateral movement. Where
this is not possible, the use of temporary “locating pins” during installation is
required.
4.3.7 Layout of Floor Plating

• Modular Design
The floor plating shall be designed in such a manner as to facilitate modular

manufacture.
• Span of Plating
The maximum span of floor plating shall be based on calculations in accordance

with LSD. The deflection of floor plating shall not exceed span/100.


Walkway floor plates may extend over more than one span, up to a maximum of
three spans to improve load distribution and deflection performance.
Where it is necessary to cantilever floor plating, the length of the cantilever shall not
exceed 10% of the tieback length or 50mm, whichever is the lesser.
• Seating of Plating
Seating of plating on supporting steelwork shall not be less than 25mm where
plating is welded to support beams and sufficient to allow an edge distance of not
less than 1.5 times the bolt diameter where plating is bolted to support beams.
The entire width of both ends of all steel floor plating panels shall be supported on
beams, except that small openings are permitted where the size of the openings
does not exceed:
1. Openings not exceeding 25mm long and not exceeding the length of the support
beam.
2. Openings not exceeding 300mm long and 50mm wide. These openings shall have
load bearing toeboards around the edges of the opening.
3. Gap in the support beam not exceeding 1000mm in width or half the width of the
panel. The steel floor plating panels over these gaps shall have a load bearing
toeboard along the end.
There shall not be more than one gap along any one side of a panel.
• Flooring Clearance
To facilitate erection, clearances shall be allowed around floor plating panels as

follows:
5.0mm between adjacent floor panel sections
5.0mm between the edge of the flooring panel and any adjacent structure
• Load-bearing Toeboards
Load bearing toeboards shall be as required for floor grating.

• Walking surfaces to be Non-Slip
All floor plating shall be vastrap plating to provide a non-slip surface.
All stair treads shall be equipped standard with fabricated non-slip nosing.
The Purchaser shall approve the non-slip finishes at tender stage.

• Inclined Walkways
The slope of inclined walkways, along conveyor gantries or where inclination of the
walkway is required for any reason shall not exceed 10°.


On all inclined walkways specific positive provision shall be made to permanently

secure plate panels against sliding down the walkway and against sliding over one
another.
4.3.8 Openings in Flooring
The following specific details shall be implemented for all steel and FRP flooring.
1. Large cut-outs or openings with dimensions greater than 500mm x 200mm shall be
protected by:
either providing guardrails all around the cut-out or opening
or providing a removable cover which is designed to carry the same load as
the surrounding floor
Where a cover is constructed of the same steel or FRP flooring as the surrounding
floor, the removable panel shall be colour coded in a high visibility colour. The edge
of the floor grating around the removable panel shall also be colour coded in a high
visibility colour.
2. Toeboards shall be provided around all cut-outs with dimensions greater than
150 mm x 80mm.
3. Banding shall be provided around all cut-outs which do not have toeboards.
The following specific details are recommended for all steel and FRP flooring.
4. Any cut-out smaller than 150mm across should be square or rectangular rather than
circular.
5. Circular panels should have load bearing toeboards along unsupported curves.
These load bearing toeboards should not exceed 1000mm in width. The overhang
of curved panels should not exceed 10% of the tieback span, or 100mm, whichever
is the lesser.
6. Where the distance from the edge of any cut-out to the edge of the flooring panel is
less than 100mm or half the size of the cut-out, the cut-out should extend right to
the edge of the panel.
7. Where panels or cut-outs are alongside concrete columns or walls, a gap of at least
20mm should be left to allow for tolerance on the concrete construction.
8. Where panels have cut-outs to allow for steel columns or bracing, adequate
allowance should be made for the projections of bolts beyond the steel face.
9. The distance between two adjacent cut-outs should not be less than 250mm.
Where cut-outs are required closer together, they shall be combined into a single
cut-out.
4.3.9 Layout of Guardrails
All Guardrails shall consist of a hand rail, a knee rail and a toeboard or bund wall.
Recommended structural sections are listed in Table 4.2.


• Guardrail Sections
The guardrail sections shown in Table 4.2 shall be used as minimum sizes for all
guardrails. The sections used for hand rails shall not exceed 75mm diameter for
round sections, or 80mm length for angle sections. The adequacy of all guardrail
sections shall be checked by the Supplier, or a Structural Engineer, taking
cognizance of the applied loads and material grade.
TABLE 4.2: RECOMMENDED MINIMUM SECTIONS FOR STEEL GUARDRAILS

Description Guardrail Hand rail Knee rail Toeboard
standard
1. General dry areas. 43∅ x 2.5 34∅ x 2.5 34∅ x 2.5

HCS HCS HCS
2. Crushing and screening.
or
3. Conveyor gantries. 130 (to
50 x 50 x 5L 50 x 5F 150) x 8F
4. Headgears. 60 x 60 x
or or
6L
5. Well ventilated, dry 25∅ Round 25∅ Round
underground areas.
1. Wet plant area with no

acid present. 32∅ Round 25∅ Round 25∅ Round
2. High temperature furnace

area. or
3. Converter area. 130 (to

150) x 8F
4. Poorly ventilated or wet 50 x 50 x 5 L 50 x 5F
underground areas. 60 x 60 x 6
or or
L
5. Wet or dry plant areas 25∅ Round 25∅ Round
where chloride liquid,
fumes or dust is present.
6. Flash drier area.

sulphurous (SO3/SO2) 38∅ x 1.6 32∅ x 1.6 32∅ x 1.6 130 (to
fumes or dust is present. HCS HCS HCS 150) x 8F
8. Areas where sulphuric

acid (H2SO4) is present.
Note: All sizes and dimensions indicated depict the minimum acceptable size.
• Guardrail Dimensions
The following dimensions should be used for all guardrails:


The top of hand rails around horizontal platforms should be not less than
1000mm and not more than 1150mm above the top of steel level. The top of
hand rails on stairs should be not less than 850mm and not more than 950mm
above the sighting edge of the stairs. Where the maximum recommended
heights are exceeded for any reason, the adequacy of the guardrail standard
sections in Table 4.2 shall be checked by the Supplier or a Structural
Engineer
The top of knee rails around horizontal platforms should be 500mm above the
top of steel level. The top of knee rails on stairs should be 500mm above the
sighting edge of the stairs
Toeboards around horizontal platforms should protrude a minimum of 100mm
above the top of floor grating or floor plating.
• Hand rails
Wherever possible, hand rails should be continuous. Hand rails on stairs shall be
continuous.
Hand rails should not have any obstruction on, above or near them that might
obstruct movement of a hand along the hand rail.
The recommended clearance between a hand rail and any wall or other obstruction
behind or below it is 65mm.
Where angle hand rail sections are used, the horizontal leg shall project outwards.
• Guardrail standards
Guardrail standards shall be attached to structural steel or structural concrete, and

not to toeboards. All standards shall be bolted to steelwork or concrete kerbs using
bolts not smaller than M16.
• Other Requirements
Wherever possible, flooring should be located between hand guardrail standards,

columns or toeboards attached to the supporting structures so that in the event of
fastening clips loosening the flooring cannot slip outwards over the end or the edge
of supporting structures.
Guardrails shall be at the edge of or within the extent of the walking surface. No
Guardrails shall be outside of the walking surface for any reason whatsoever.
Toeboards and bund walls shall be provided around the entire outer perimeter of
floors, except at stairs. Toeboards and bund walls shall be provided around all cut-
outs of floors.
Wherever possible, off-set or gooseneck guardrail stanchions are to be avoided for

safety reasons.


4.3.10 Layout of Stairs and Ladders

• Stairs
Stairs shall have an angle of inclination, α,

of not less than 30° and not more than
45°.
The step rise, h, shall be not less than

180mm and not more than 220mm. The
step rise shall remain constant throughout g c
the length of any one flight of stairs. b
The tread length shall be not less than
750mm.
The going of any tread, g, shall be not h

less than 200mm.
α
The horizontal overlap between any two
consecutive steps, c, shall be not less
than 0mm and not more than 50mm.
The maximum height of any stair between

landings shall not exceed 3m.
The minimum headroom above stairs

shall not be less than 2.1m.
• Stair Treads
A rectangular pattern bar grating with bearer bars running across the length of the
stair, and with an abrasive nosing and side plates shall be provided.
All stair treads shall be drilled for bolting to the stair stringers using a minimum of
4 Class 8.8 M12 bolts with self-locking nuts.
Side plates shall have a minimum thickness of 4.5mm and shall be welded to the
ends of all the bearer bars with a continuous 4mm fillet weld on both sides


• Inclined Steel Ladders
Inclined Steel Ladders shall have an angle

of inclination, α, of not less than 65° and
not more than 75°.
The step rise, h, shall be not less than

230mm and not more than 260mm. The
step spacing shall remain constant
throughout the length of any one ladder.
h
The step length shall be not less than
450mm.
b
The step depth, b, shall be not less than
80mm.
The maximum length of any ladder α

between landings should preferably be not
exceed 3.0m, but shall not exceed 5.0m.
Inclined ladders shall have a single hand

rail on each side, at a vertical height
above the nosing of not less than 400mm
and not more than 600mm.
• Guardrails and Handrails on Stairs and Inclined Ladders
Any stair or inclined ladder which has a height exceeding 750mm or from which any
person could fall more than 750mm shall have barricading (i.e. a wall or guardrails)
on both sides.
All stairs and inclined ladders shall have hand rails along both sides, either as the
top rail of guardrails, or attached to the wall.
• Vertical Steel Ladders
The step spacing, h, shall be not less than 230mm and not more than 300mm. The
step spacing shall remain constant throughout the length of any one ladder.
The step length shall be not less than 300mm.
Round steps shall be used. The step diameter shall be not less than 20mm and not
more than 50mm.
The maximum length of any ladder between landings should preferably be not more
than 6.0m but shall not exceed 8.0m.
Any vertical ladder which has a height of more than 4.0m shall have a safety cage,
extending from 2.5m above the lower end of the ladder to at least 1.0m above the
floor or landing at the top of the ladder.


• Landings
The length of landings shall be not less than the length of the stair tread or the
diameter of the ladder cage.
The width of landings shall be not less than 900mm.
4.3.11 Use of Stairs or Ladders
Where access between higher and lower levels is required, it is recommended that stairs
should be provided in preference to ladders wherever possible.
Stairs shall be provided and ladders shall not be used, under the following conditions:
• Where a risk assessment shows the use of ladders to be unsafe for any reason
• Where emergency egress for more than 3 people is required
• Where daily access for more than 10 people is required
• Where any injured persons may have to be evacuated
• Where heavy, or large, tools or toolboxes must be carried
4.3.12 Roof Access and Edge Protection
Where maintenance is required on any roof access shall be provided. All platforms,
walkways and stairs on roofs shall comply in all respects with the requirements of this
specification.
Guardrails shall be installed along the edges of all platforms, walkways and stairs on
roofs where any of the following applies:
• Where the roof has a slope exceeding 15º guardrails shall be installed along the
down slope edge
• Where any edge is less than 2.0m from the edge of the roof guardrails shall be
installed along that edge
• Where translucent or brittle roof cladding is used guardrails shall be installed along
all edges
• Where gutters are accessible and may be used as walkways guardrails shall be
installed along the outer edge of the gutters
4.4 REQUIREMENTS FOR FABRICATION AND SUPPLY

4.4.1 Materials
The Supplier shall ensure that all material used in the fabrication of steel or FRP flooring
and walkways, stairs and handrails complies with the requirements of this specification
and is as specified on the relevant design drawings. Materials conforming to standards
other than those covered by this specification shall be tested in order to demonstrate their
conformance to the relevant standards specified herein and their use shall be approved in
writing by the Design Engineer.


Additional costs incurred in obtaining approval and using approved substitutions shall be
borne by the Supplier.
4.4.2 Compliance with Design Drawings
All work shall comply in all respects with the design drawings. If the Supplier requires
clarification of any information on the design drawings, such clarification shall be obtained
from the Design Engineer.
If the Supplier has good reason to modify or change any part of the work specified on the
design drawings, this shall be agreed with the Design Engineer, who shall revise the
design drawings accordingly and issue the revised drawings for fabrication.
4.4.3 Modular Design
The components shall be manufactured on a modular basis and shall utilise readily
available standard sub-components where possible to facilitate the procurement of spares
and replacement parts for maintenance purposes and to facilitate inter-changeability.
The Supplier shall prepare modular layout drawings which shall be submitted to the
Project Engineer for approval. The Project Engineer shall review and approve the
modular design and layout prior to the commencement of fabrication to ensure it
compliments the design intent. Such approval shall be defined as a “Hold” point in the
fabrication Quality Control Plan.
4.4.4 Construction Details

• Banding Bars
All steel or FRP grating panels shall be banded around the entire perimeter, except
where:
toeboards are fixed to the grating panel
the bearer bar forms the banding bar
specified otherwise by the Purchaser
Banding bars shall be 10mm shallower than the bearer bars. All banding bars shall
be flush with the top of the grating panel, allowing a 10mm gap below for drainage
of water or spillage.
• Welding of Bars in Steel Grating
Welding of bars in steel grating panels shall comply with the requirements listed in
Table 4.3.


TABLE 4.3: WELDING OF BARS

Welding Required
Transverse bars Bearer bars to Bearer bars to
Description to bearer bars and banding or load bearing
banding or toeboards toeboards
toeboards
1. General dry areas. Weld one bar in Weld one bar in Weld all bars.
three. three.
5mm continuous
2. Crushing and screening. 3mm continuous 3mm continuous fillet weld on
fillet weld all fillet weld on one both sides
3. Conveyor gantries. round side only
4. Headgears.
5. Well ventilated, dry

underground areas.
1. Wet plant area with no acid Weld all bars. Weld all bars. Weld all bars.
present. 3mm continuous 3mm continuous 5mm continuous
fillet weld all fillet weld all fillet weld all
2. High temperature furnace
round round round
area.
3. Converter area.
4. Poorly ventilated or wet

underground areas.
5. Wet or dry plant areas where

chloride liquid, fumes or dust
is present.
1. Flash drier area. Weld one bar in Weld one bar in Weld all bars.
three. three.
5mm continuous
3mm continuous 3mm continuous fillet weld on
sulphurous (SO3/SO2) fumes
fillet weld all fillet weld on one both sides
or dust is present.
round side only
3. Areas where sulphuric acid
(H2SO4) is present.
4.4.5 Welding
• General
All welding shall comply with the design drawings, and be done in accordance with
the requirements of AWS D1.1
• Welding Consumables
All welding consumables shall comply with the requirements of SSC.

• Qualification of Welders


All welders shall be suitably qualified and coded to the requirements of AWS D1.1.
4.4.6 Painting and Protective Coating

• Protective Coating to be Applied
Painting and protective coating shall be in accordance with the design drawings or
Section 4.3.3 of this specification.
• Repair of Corrosion Protection
1. Paint Systems
Paint systems shall be made good by wire brushing of the affected area to remove
any loose material and hand painting with the specified paint system.
2. Hot Dip Galvanising
Should any shaping of the panel be carried out after hot dip galvanising, the
appropriate area shall be made good in accordance with AA CPS 41A.
If the panel also had a coat of bitumen before shaping, the repair procedure of
AA CPS 41A shall be followed by one coat of bitumen.
4.4.7 Certification
All materials used shall be traceable.
Chemical composition and mechanical properties certification of materials shall be

submitted to the Project Engineer on request.
4.4.8 Tolerances
All tolerances shall be measured after completion of manufacture (including galvanising

or painting and banding where appropriate) of steel and FRP flooring, stairs and
guardrails.
• Floor Grating
TABLE 4.4: FLOOR GRATING AND STAIR TREAD TOLERANCES

Description Steel Grating FRP Grating
Overall panel length ± 5.0mm ± 5.0mm
Overall panel width ± 5.0mm ± 5.0mm
Overall panel squareness ± 5.0mm ± 5.0mm
Stair tread length ± 2.0mm ± 2.0mm
Stair tread width ± 5.0mm ± 5.0mm
Cut-out size (width and length) ± 5.0mm ± 5.0mm
Panel camber (upward or downward bow) Lesser of: Lesser of:

before fixing ± 10.0mm ± 10.0mm


Description Steel Grating FRP Grating

Width/200 Width/200
Length/200 Length/200
Lesser of: Lesser of:
± 5.0mm ± 5.0mm
Panel curve (lateral bow) before fixing
Width/200 Width/200
Length/200 Length/200
Lesser of: Lesser of:
Bearer bar and banding depth ± 1.0mm ± 1.0mm
2% of depth 2% of depth
Bearer bar and banding thickness ± 0.3mm ± 0.3mm
Bearer bar and banding twist ± 4° ± 4°
Lesser of: ± 2.0mm
Bearer bar spacing ± 2.0mm
4% of nominal spacing
Transverse bar spacing ± 3.0mm ± 2.0mm
Transverse bar size ± 0.5mm As bearer bar
• Guardrail Tolerances
All guardrail components shall be manufactured to the tolerances for structural

steelwork specified by SSC.
• Stair Tolerances
All stairs shall comply with the tolerances for structural steelwork specified by SSC.
4.4.9 Test and Inspection Methods
Testing and inspection shall be in accordance with the requirements of BS 4592.
4.4.10 Packing and Marking

• Packaging
Packing shall be such as to ensure adequate protection in transit and to prevent

deterioration for a period of two months after delivery to site. Packing shall be on
the basis that the there will be no additional protection from transport damage or
from the site environment during that period.
Any damage as a result of inadequate packaging and marking shall be for the
Supplier’s account.
Each consignment shall include a complete packing list identifying each loose item,
component or part and shall reference the relevant order number and equipment
number.


• Marking
1. Marking drawings
The Contractor shall prepare marking drawings and supply one print to the Project
Engineer for approval. An electronic file shall also be supplied to the Project
Engineer on request
2. Item marking
Each item shall be clearly marked in accordance with the requirements of the
design drawings. Where necessary, match marking shall be used to facilitate site
assembly. Marking shall include:
Identifying number or mark
Manufacturer's name or logo
Batch number or date of manufacture
Grating panels shall be marked on the banding or toeboards, or on metal tags.

Hand rails, knee rails and standards shall be marked on metal tags. All metal tags
shall be securely fastened with wire.
4.4.11 Performance and Guarantee
The performance of the items supplied in terms of this specification, as defined by the
order, shall be warranted by the Supplier and if specified, be tested in accordance
therewith.
The Supplier shall warrant that the goods supplied will perform for the purpose for which
they are intended.
The Supplier shall not be required to conduct a performance test on site.
A minimum guarantee period of 12 months is required.
4.5 REQUIREMENTS FOR INSTALLATION

4.5.1 Safety
Installation of steel and FRP flooring, stairs and guardrails requires that workers work at
heights. All work shall be done in compliance with the Anglo Fatal Risk Standard
AA AFRS 07 “Working at Heights”.
Installation shall be done by workers who are secured to steelwork or a lifeline system via
a full fall restraint system. Full fall restraint shall be used by all workers on the flooring,
until it has been inspected and approved for use.
The work area shall be closed off to all other Contractors and site personnel until it has
been inspected and approved for use.
The area beneath the working area shall be barricaded or demarcated to prevent access.


4.5.2 Installation Procedure

• Method Statement
The Contractor shall prepare an installation method statement giving details of the
proposed installation method to ensure that nothing about the manner in which it is
to be installed makes it unsafe, or creates a risk to health and safety. The
installation procedure shall also be such as to ensure that components are not
damaged in any way. Such method statement shall be issued to the Project
Engineer for information and acceptance prior to the commencement of installation
and shall form part of the Contractors Risk Assessment for the execution of the
works.
• Inspection and Acceptance
The Contractor shall inspect and accept the structures for access to commence
installation. Discrepancies shall be made known to the Project Engineer in writing
prior to commencement of installation. The Project Engineer shall be notified of any
further faults in the work area, which are revealed during the installation of flooring,
stairs or guardrails in the area.
• Installation of flooring
Locating pins, or some other means of holding loose panels in position, shall be
progressively installed during placement of panels, to avoid individual panels or
assemblies of panels sliding off the supporting steelwork. These may only be
removed after the proper alignment and fixing of flooring panels in accordance with
an approved fixing method hereafter.
Temporary location of flooring panels on inclined floors shall be subject to specific

risk assessment, to ensure they do not slip or fall off.
Each part of the flooring shall be aligned and fixed as soon as it is practicably
possible. Members shall not be permanently fastened until enough of the flooring
has been aligned and temporarily connected to ensure that they will not be
displaced during the placement or alignment of the remainder of the floor. Modular
group installations shall be restricted to the area that temporary locating devices
have been provided for. Should the secured panels require removal, a new risk
assessment shall be done to suit.
All workers installing flooring shall use fall arrest systems.

• Installation of Stairs
Stairs should be installed from the ground level, working upward.
All stair treads should be properly fastened as soon as they are installed.
All workers installing stairs shall use fall arrest systems.

• Installation of Guardrails
The installation procedures recommended by the Suppliers should be followed.


All guardrails should be installed as soon as possible after installation of flooring

and stairs. All guardrails should be properly and securely fastened as soon as
possible after they have been located in position.
All workers installing guardrails shall use fall arrest systems.
4.5.3 Fastening of Flooring, Stairs and Guardrails

• Location of Fasteners
Panels shall be securely fastened to the supporting structure at each corner or as

close as possible to each corner.
A minimum of four fasteners shall be used per panel. Where large panels are used,
additional fasteners shall be utilised to secure the panels at intervals not exceeding
1.5m along each end and edge.
Where any floor vibration is present, the preferred method of fastening steel grating
or plating is welding.
• Floor Grating Fasteners
1. Top fixing of fasteners
Fasteners should be of a type that can be inserted and fastened from above.
Where access below grating is required to insert or fasten any fasteners, a specific
risk assessment shall be conducted to address how this will be accomplished
safely.
2. Non-loosening fasteners
Fasteners shall be of a type that will not loosen with use of the floor.
3. Fasteners to be flush with floor
Fasteners shall be of a type that is flush with the floor surface, or is set below the
floor surface. Fasteners shall not protrude above the floor surface by more than
2mm. Bolts for floor plating shall have countersunk heads.
4. Proprietary bolt and clamp or clip systems
The Supplier of any proprietary fastening system shall provide a written

performance guarantee for use of the fastening system in the specific environment
in which it is to be used. The description of the specific environment shall include at
least the following:
whether there is any vibration of the floor
corrosive chemicals to which the floor may be exposed
exposure to washing or process water
whether there is exposure to direct sunlight
duty usage of the floor


whether the floor is flat or inclined, in which case the angle of inclination shall
be included
5. Bolts
Securing bolts shall not be smaller than 8mm diameter and shall use locking nuts or
a double-nut arrangement for locking.
6. Materials
The bolt and saddle clamp materials shall be selected to complement the grating
material specified in order to avoid bi-metallic corrosion. Where steel or stainless
steel grating is used, fasteners shall be of the same material and shall have the
same corrosion protection system.
• Floor Grating Welding
Field welding shall only be performed where specified by the Design Engineer.
The location of welds shall comply with the Location of Fasteners in Section 4.5.3.
The size of welds shall be:

5mm fillet weld
Minimum length to be 25mm
Inspection of welds shall include:

The fastening welds of the first three floor panels fixed are to be 100% visually
inspected and 100% dye penetrant tested. If satisfactory, the welds on
subsequent floor panels are to be 100% visually inspected and 10% dye
penetrant tested. If not satisfactory the welds on subsequent floor panels
shall be 100% visually inspected and 100% dye penetrant tested until
satisfactory results are achieved. Thereafter subsequent floor panels are to
be 100% visually inspected and 10% dye penetrant tested.
The inspection standard for the above inspection shall be as per AWS D1.1
Table 8.1.
Corrosion protection:
All welds shall be corrosion protected after inspection. Care shall be taken to
ensure that all damaged paintwork on the grating as well as the supporting
structural steelwork is corrosion protected
Where the grating is painted, the weld damaged areas shall be repaired using
the same paint system
Where the grating is galvanised, cold galvanising shall be applied, in
compliance with AA CPS 41A
Qualification of welders:
All welding shall be carried out by suitably qualified welders coded to the
minimum requirements of AWS D1.1.


Where welding takes place there is to be good ventilation in the vicinity of the
welding operation, where possible suction tube gun nozzles, facemasks and
respirators are to be used. Welders are to position themselves so as not to be
overexposed to the weld fumes. Note that zinc fumes are not toxic and the
symptoms of overexposure (fever, headaches) will disappear within a few
hours.
Protection from Corrosion
1. Bearing area
Except in the case of FRP grating, when the material of construction of the grating
is different to the material of construction of the supporting structure, the bearing
area on the supporting structure should be covered with a 3mm thick Bitumen or
Neoprene strip equal in length to that of the minimum bearing length. The strip
should be laid before the grating is installed.
2. Anti-seize paste
All bolts and bolt holes (required for FRP grating installation) shall be coated with a
Depac anti-seize paste before assembly. Depac past is a non metallic based paste
and can be used on carbon steel and stainless steel bolts and nuts up to a
temperature of 14000C. The use of metallic based paste is not recommended due
to the associated health risk and relative low chemical resistance to acids.
3. Repair of galvanising
Where galvanising has been damaged during welding, it shall be repaired in

compliance with AA CPS 41A.
4.5.4 Installation Tolerances

• Maximum clearance
The clearance between adjacent flooring panels after erection shall not exceed
10.0mm.
• Minimum seating
The seating of flooring panels shall not be less than 50mm.
4.5.5 Inspection and Acceptance
Prior to the barricading being removed and general access being allowed, the area shall
be inspected by the Project Engineer to ensure that the area is safe. This inspection shall
cover at least the following:
• All components (flooring, stairs and guardrails) shall be in place. All floor grating
shall be spanning in the correct direction
• All components shall be properly fastened
• Any openings shall be safe, i.e. they shall be properly covered or guardrails or
toeboards as required shall be in place


4.6 REQUIREMENTS FOR USE

4.6.1 Support of Equipment
• Equipment on Floors
No pipes of diameter greater than 50mm may be laid across nor supported from
any floor grating, floor plates or walkway grating.
Floor grating and floor plating shall not permanently support any form of heavy
equipment. Light equipment, cabinets or switchgear, with a mass not exceeding
500kg on floor grating, and not exceeding 250kg on floor plating, may be supported
providing the following precautions are taken:
Each leg shall have a steel plate foot, at least 8mm thick, and at least
150mm x 150mm in size.
No cut-outs shall be made in the grating to accommodate the equipment.
The equipment shall not have any vibrating or moving components.
Walkway grating shall not support any equipment of any kind.

• Equipment on Guardrails
No equipment having a mass exceeding 100kg shall be supported on guardrails.

Light equipment, with a mass not exceeding 100g may be supported on guardrails,
provided the following precautions are taken:
The cumulative mass of several small items of equipment along one length of
guardrail shall not exceed 30kg/m.
The fixing of the equipment shall be such that, should a person run their hand
along the hand rail, no part of their hand or fingers can get stuck between the
hand rail and the equipment.
Any projection of the equipment in front of the guardrail shall be limited so that
it does not cause any obstruction to people moving along the floor area. No
equipment whatsoever shall project in front of any guardrail along the edge of
an emergency escape route.
• Equipment on Stairs
No equipment of any kind shall be supported on stairs.
No equipment of any kind shall be supported on or attached to the guardrails on

stairs.
4.6.2 Storage
Steel flooring shall not be used for the permanent storage of any spares or equipment,
unless the area has been specifically designed and marked for this purpose. Where it is
necessary during maintenance for small items of equipment to be temporarily placed on
floor grating or floor plating, this shall be risk assessed giving due cognizance to the
design load for the specific floor. Where there is any doubt a Structural Engineer shall be
consulted.


Guardrails shall not be used as a support to which goods or articles may be secured for
any reason whatsoever.
No equipment or spares of any kind shall be stored on stairs.
4.6.3 Lifting
No attachments shall be made to any guardrail, flooring or stair to hoist or lower any
goods or heavy equipment.
Guardrails may only support fibre or nylon ropes used for lifting hand tools and small
equipment with a mass not exceeding 20kg.
No chain block, slings or any other lifting equipment shall be attached to any walkway
grating or stairs.
4.6.4 Openings
• Risk Assessment
When it is necessary to make any openings in any flooring, a risk assessment shall
be carried out. The risk assessment shall include the use of the floor after the
opening has been made, as well as the process of making and protecting the
opening.
• New Openings in Flooring
New openings shall not be made in flooring, unless all other options have been
considered and shown to be impractical or not feasible. Where it is necessary to
make new openings in flooring, this shall be done in compliance with the following
requirements:
1. Forming temporary openings
Where any new temporary opening is required for maintenance or any other
purposes only complete grating panels shall be removed. Grating panels shall not
be cut and repaired. Any grating panel temporarily removed shall be marked so
that it can be replaced in exactly the same orientation as prior to its removal.
Immediately on completion of the work for which the grating panel was removed,
the panel shall be replaced and securely fastened.
2. Support of floor panels
All floor grating panels or floor plates surrounding the new opening shall be
supported as required for Design in the section above. Where new floor support
beams are required to provide adequate support around the ends or edges of a new
opening, these shall be specified by a Design Engineer.
3. Protection of permanent openings
All new permanent openings shall be protected as required for Design in the section
above.


4. Protection of temporary openings
All temporary openings in the floor grating or floor plating panels, where the length
does not exceed 1.0m, shall be closed-up using scaffolding planks which shall be
securely attached to the surrounding steelwork. No loads from any spares or
equipment shall be placed on scaffolding plank covers.
All temporary openings in the floor grating or floor plating panels, where the length
exceeds 1.0m, shall be closed-up using a cover specified by a Design Engineer
which shall be securely attached to the surrounding steelwork. This cover shall be
designed to carry the same floor loads as the surrounding flooring.
Alternatively, the temporary opening shall be barricaded by means of guardrails.
5. Precautions during installation work
Whilst work of making new openings is in progress, the precautions required for
Installation in the section above shall apply.
• Closing of Existing Redundant Equipment Openings
Where openings have been left in floors due to equipment having been removed
and not replaced, the opening shall be protected as follows:
Redundant openings should be closed using the same flooring as is used for
the surrounding floor areas. New floor support beams, the same size and at
the same spacing as the surrounding floor, shall be installed to support the
new flooring. A Design Engineer shall be consulted if there is any doubt as to
the size, spacing and end fastenings for the new beams. Layout and design
of the new flooring shall comply with the requirements of this specification for
design, as listed in the section above.
Where the redundant opening is to remain open, the preferred method of
protection is to place a guardrail around the opening. This is the preferred
method as it eliminates steps in flooring and tripping hazards. This method
shall be used wherever possible.
Alternatively if the opening is to remain open, removable covers may be
placed over the opening. The covers shall be designed by a Design Engineer
and shall be designed to carry the loads for which the surrounding floor areas
are designed. This method shall only be used on openings smaller than
1500mm square.
4.6.5 Covering of Floor
Instances have been encountered where flooring is covered by off-cuts of conveyor

belting or steel plates. The following shall be observed in respect of these floor
coverings:
1. Where off-cuts of conveyor belting or steel plates are used to provide a smooth
working surface or to prevent small objects such as bolts, nozzles etc falling
through the floor during maintenance, the floor covering shall be removed as soon
as the maintenance task has been completed.


2. Where off-cuts of conveyor belting or steel plates are used to prevent spilled oil or
dust to penetrate the floor, the cause of the spilled oil of dust shall be rectified as
soon as possible and the floor covering shall be removed as soon as this has been
completed.
3. Off-cuts of conveyor belting or steel plates shall not be used to cover holes. Any
holes in the flooring shall be protected as specified above.
4. Off-cuts of conveyor belting or steel plates shall not be used to cover deteriorated
portions of flooring. Any deterioration in the flooring shall be repaired as specified
in the Section “Requirements for Maintenance and Repair”.
4.6.6 Reinstatement following Removal for Maintenance
When any maintenance work has required the temporary removal of any steel or FRP
floor panels, stair components or guardrail components, the Designated Foreman shall
carry out an inspection following reinstatement of what was removed. No workers other
than those specifically required to perform the maintenance tasks shall use the floor until
the Designated Foreman has completed this inspection and declared the floor to be safe
for use.
4.6.7 Regular Inspections

• Inspection Intervals
All steel and FRP floors and walkways, stairways and guardrails shall be visually
inspected at intervals not exceeding the intervals defined in Table 4.5.
TABLE 4.5: VISUAL INSPECTION INTERVALS FOR STEEL FLOORING, STAIRS

AND GUARDRAILS
Inspector Inspection Interval
Designated Foreman 6 months
Professional Structural Engineer 3 years
In addition, an inspection shall be carried out immediately following any significant

event that affects the steel or FRP flooring, stairs and guardrails. Examples of
significant events include: vehicle impact leading to structural damage; smelter
runout; large item dropped on the flooring or stairs; accumulation of spillage
exceeding 0.5m deep or earthquake.
• Inspection Requirements
A checklist shall be prepared and used for every inspection to ensure that all
important items are covered. Every inspection of steel and FRP flooring, stairs and
guardrails shall include at least the items listed in Table 4.6. A separate checklist
should be completed for each different floor level or area.


TABLE 4.6: ITEMS TO BE INSPECTED

Item Checks to be done
All edges shall have guardrails.
All holes shall be covered or protected by toeboards or guardrails as
Safety
required.
Flooring shall be level without tripping hazards.
There shall not be loose hoses, spares, pipes etc. lying on floors or
against guardrails.
Housekeeping There shall not be excessive spillage lying on flooring.
There shall not be heavy piping or other equipment supported on
flooring.
Steel FRP
Floor Stair
Guardrails floor floor Ladders
plates treads
grating grating
Joints and Check Check Check Check Check Check
fixings tight
Seating on N/A Check Check Check N/A N/A
beams
Damage Check Check Check Check Check Check
Wear of surface N/A Check Check Check Check Check
Corrosion Check Check Check N/A Check Check
Nosing secure N/A Check Check Check Check N/A
and visible
Ladder cage N/A N/A N/A N/A N/A Check
Spillage N/A Check Check Check N/A N/A
No cutting and Check Check Check Check Check Check
modifications
• Inspection Records
The results of all inspections shall be recorded and kept on file, either electronically
or in hard copy form.
Inspection findings should be reported as described in AA BPG S03. As a

minimum, the inspection findings shall include problems identified, remedial work
required and the urgency of remedial work. The section dealing with maintenance
below provides guidance as to what remedial work is appropriate under different
conditions.
Where any remedial work is required following an inspection, the inspection record
shall be signed off after completion of the work by the person allocated to do the
work.


4.6.8 Retrofit Requirements for Non-Compliant Items
There are likely to be situations where existing steel or FRP flooring, stairs, ladders or
guardrails do not comply with this specification, either because the plant was constructed
prior to approval of this specification or because the plant was purchased from an owner
with a different specification.
All replacements shall comply with the requirements of this specification.
Where any items do not comply with this specification, the actions listed below should be
implemented within the time frame specified.
• Non-Compliant Material
Actual Material Specified Material Action Required
Material ≥ 2.5mm thick – replace when required
Mild steel Stainless steel
Material < 2.5mm thick – replace within 3 years
Mild steel FRP Replace within 2 years
Mild steel 3CR12 Replace when required
Stainless steel Any No action required
FRP Any No action required
3CR12 Any Replace when required
Wrong grade bolts Any Replace bolts within 6 months
Note: Where action is given as replace when required, replacement is only necessary when regular
inspections indicate that it should be done.
• Non-Compliant Corrosion Protection
Actual Corrosion Specified Corrosion
Action Required
Protection Protection
Material ≥ 2.5mm thick – replace when required
Any paint system Hot dip galvanised
Other paint Epoxy coal tar Replace when required
system
• Non-Compliant Section or Grating Sizes

Actual Section Specified Section Action Required
Hollow sections Solid or angle Material ≥ 2.5mm thick – replace when required
sections
Bearer bars < Bearer bars ≥ 4.5mm Replace when required
4.5mm thick


• Non-Compliant Construction Details

Non-Compliant Detail Action Required
Stairs and ladders
Stair angle too steep Place warning signage
Replace within 5 years
Ladder cage missing Cordon off area
Replace within 1 month
Stair treads too small, too far apart or too Place warning signage
close together
Replace within 5 years
Stair or walkway too narrow No action required, unless deemed necessary
for safe access
Floor panels and plates
Floor panel seating < 50mm but > 10mm Inspect for safety at 3 monthly intervals
Floor panel off support beams or seating < Cordon off area
10mm
Repair within 1 month
Floor grating panels span wrong direction Inspect for safety at 3 monthly intervals
Replace panels within 2 years
Floor grating panels not adequately Inspect for safety and damage at 3 monthly
supported along full width of sides intervals
Implement remedial work within 2 years
Floor grating or plating surface smooth Place warning signage
Replace within 1 year
Guardrails
Hand rail missing Cordon off area
Replace within 1 month
Knee rail missing Place warning signage
Replace within 3 months
Toeboard missing Place warning signage
Replace within 3 months
Guardrails outside of working surface Place warning signage
Replace within 1 year
4.7 REQUIREMENTS FOR MAINTENANCE AND REPAIR

4.7.1 Fabrication and Supply
The fabrication and supply of replacement steel and FRP grating, stairs, ladders and
guardrails shall comply in all respects with the requirements for new steel and FRP
grating, stairs, ladders and guardrails in the section above.


Wherever possible, replacement steel and FRP grating, stairs, ladders and guardrails
should be in accordance with the drawings for the existing steel and FRP grating, stairs,
ladders and guardrails. Where the existing layout or design does not comply with this
specification, or changes to the layout are required for any other reason, the drawings
shall be updated and approved prior to fabrication commencing. The original Supplier
should be the preferred Supplier of replacements in all cases.
4.7.2 Installation
• Installation of Large Areas
Where large areas of flooring, entire stairs or ladders, or long lengths of guardrails
require replacement, the installation of such replacement steel and FRP grating,
stairs, ladders and guardrails shall comply in all respects with the requirements for
new steel and FRP grating, stairs, ladders and guardrails in the section above.
• Installation of Isolated Components
Where isolated components of flooring, stairs, ladders, or guardrails require

replacement, the installation may be done in compliance the requirements for new
steel and FRP grating, stairs, ladders and guardrails in the section above, or a
specific installation procedure may be prepared. If a specific installation procedure
is prepared, this shall be based on a risk assessment to determine the safety and
other requirements of the installation project.
The Mine Engineer shall ensure the proper reinstatement of the flooring, stairs,
ladders or guardrails. On completion the Mine Engineer shall inspect and accept the
work as required for new installations in the section above.
4.7.3 Grating
• Replacement of Grating
Steel and FRP grating shall not be repaired by welding or any other means. Grating
panels shall be replaced under any of the following conditions:
1. Corrosion
Where corrosion has reduced the bearer bar thickness by more than 1.0mm
Where corrosion has reduced the area of the transverse bars by more than
35%
2. Bending of bearer bars

Where bearer bars, banding or toeboards have been twisted through more
than 15°
Where a single bearer bar has been bent laterally by more than the spacing
between bearer bars, or where several bearer bars, banding or toeboards
have been bent laterally by more than half the spacing between bearer bars
Where the panel has been bent upwards or downwards by more than the
depth of the bearer bars


3. Cutting of bars or panel

Where any of the bearer bars have been cut so that they are no longer seated
on the supporting structure
Where any portion of the panel has been cut out and it is not possible to
comply with the requirements for new openings in the section above. This
shall apply even where the cut-out has been re-welded in place. Patch repairs
of this nature are not allowed
4. Connection between bars

Where the connection between the transverse bars and the bearer bars has
broken or loosened at more than 3 locations along a single bearer bar, or at
more than 10 locations within a single panel
Where the welding between more than one bearer bar and a load bearing
toeboard has broken
Where the welding of bearer or transverse bars to the banding or toeboard
has cracked or broken at more than 2 locations along a single side, or at more
than 5 locations around one panel
5. Fire damage
Where FRP components have been exposed to any fire
Where steel components subjected to a fire have distorted to the extent that
the distortion is clearly visible
Where the existing grating panels have bearer bars with a depth of less than the
minimum requirement of this specification, new grating panels with deeper bearer
bars shall be used. In this event, sufficient grating panels shall be replaced to blend
smoothly into the grating panels with shallower bearer bars. By this it is intended
that all grating panels shall be replaced up to a natural break in the floor where a
change in grating panel depth will not be noticed.
• Dimensions
Dimensions and layout of replacement panels should be as specified on the

approved drawings. If it is necessary to change the panel dimensions for any
reason, the Supplier shall prepare revised drawings showing the new panel layout
and have these drawings approved.
4.7.4 Fasteners
• Tightening of Fasteners
All loose fasteners shall be tightened as soon as possible but never more than one
month after the inspection.
Any fasteners that loosen again within six months of being tightened shall be
replaced with different fasteners that have improved resistance to loosening.


• Replacement of Fasteners
Where any of the following conditions apply, the relevant fasteners shall be
replaced:
Any missing fasteners
Any broken fasteners
Any fasteners that have corroded, bent or been damaged in any way
Any fasteners where the heads project above the top surface of the flooring
Replacement fasteners shall be the same as or better than those specified on the
drawings in all respects.
4.7.5 Stairs
• Replacement of Stair Treads
Where any of the following conditions apply, the relevant stair treads shall be
replaced:
Any missing stair treads
Any broken stair treads
Any stair treads that have corroded to the extent that the bearer bars have lost
more than 1.0mm of their thickness
Any stair treads that have been bent upwards or downwards by more than the
bearer bar depth
Any stair treads where the non-slip surface has come off the nosing so that it
has become slippery
Replacement stair treads shall be the same as those specified on the drawings in all
respects.
4.7.6 Ladders
• Replacement of Ladders
Where any of the following conditions apply, the relevant ladder shall be replaced in
its entirety:
Either of the ladder stringers has corroded to the extent that its thickness has
reduced by more than 1.0mm
Either of the ladder stringers is broken, or both ladder stringers are bent by
more than 100mm
More than 20% of the rungs are corroded to the extent that their diameter has
reduced by more than 2.0mm
More than 20% of the rungs are broken or bent by more than 40mm
The cage is generally corroded to the extent that thicknesses have reduced by
more than 1.0mm


The cage is broken or bent by more than 75mm at more than 3 places
Where damage cannot be repaired for any reason
Replacement ladders shall be the same as or better than those specified on the
• Repair of Ladders
Where any of the following conditions apply, the damage to the ladder shall be
repaired as described:
Where less than 20% of the rungs are corroded to the extent that their
diameter has reduced by more than 2.0mm, the corroded rungs shall be cut
out and new rungs shall be welded in place.
Where less than 20% of the rungs are broken or bent by more than 40mm,
the broken or bent rungs shall be cut out and new rungs shall be welded in
place.
Where the cage is locally corroded to the extent that thicknesses have
reduced by more than 1.0mm, the corroded areas shall be cut out and new
sections welded in place
Where the cage is broken or bent by more than 75mm at less than 3 places
the bent sections shall be cut out and new sections welded in place
Corrosion protection shall be made good after welding
4.7.7 Guardrails
• Replacement of Guardrails
Where any of the following conditions apply the guardrails shall be replaced in their
entirety:
Where any length of guardrail is missing
Any general corrosion of components with thickness greater than 5.0mm to
the extent that the thickness has reduced by more than 1.0mm
Any general corrosion of components with thickness less than or equal to
5.0mm to the extent the thickness has reduced by more than 0.5mm
General damage, where the standards, hand rails and knee rails are all bent
to the extent of more than 100mm
Replacement guardrails shall be the same as or better than, those specified on the
• Repair of Guardrails
Where any of the following conditions apply, the guardrails shall be repaired as
described:
Where any length of hand rail or knee rail is missing this shall be replaced by
welding in a new section. All welds on hand rails shall be ground smooth after
welding


Any local corrosion of components with thickness greater than 5.0mm to the
extent that the thickness has reduced by more than 1.0mm. The corroded
portion shall be cut out, and a new section welded in place
Any local corrosion of components with thickness less than or equal to 5.0mm
to the extent the thickness has reduced by more than 0.5mm. The corroded
portion shall be cut out and a new section welded in place
Local damage, where only a standard is bent to the extent of more than
100mm. Damaged standards shall be removed and replaced by new
standards
Local damage, where only a hand rail or a knee rail is bent to the extent of
more than 100mm. The damaged portion of hand rails or knee rails shall be
cut out and a new section welded in place
Cracked hand rails or knee rails shall be welded
All welds on hand rails shall be ground smooth after welding. Corrosion protection
shall be made good after welding
5 QUALITY ASSURANCE PROVISIONS
5.1 QUALITY MANAGEMENT

The requirements of ISO 9001 shall apply. All optional requirements in ISO 9001 shall be
compulsory requirements for material supplied against this specification.
Quality management and quality assurance arrangements shall be in accordance with

AA STD 100.
All test and inspection reports shall be suitably signed off by the responsible parties and
included in a Quality Data Pack, which shall be submitted prior to the issuing of an
Acceptance Certificate at completion of the works.
5.2 QUALITY PLAN

Suppliers and Contractors shall compile and submit a quality plan for the design and
installation of all steel and FRP flooring, stairs and guardrails. This quality plan shall:
• be separate from the quality plan for design and installation of structural steelwork
or other structures
• list all major works, specifications, tests, methods of test, equipment to be used and
acceptance/rejection criteria
• all areas of flooring, stairs and guardrails to be inspected and signed off separately
from any other structures
• provide proof of qualification of all welders
The quality plan shall be approved by the Project Engineer prior to commencement of
manufacture.


5.3 TEST FACILITIES

The Supplier shall provide test samples, qualified labour and approved testing equipment
for tests. If facilities are not available at the Supplier's premises the Supplier shall arrange
for tests to be conducted by approved test authorities. The costs of all tests shall be
borne by the Supplier.
5.4 INSPECTION
The QAR shall have access at all reasonable times to those parts of the manufacturing
facilities engaged in the manufacture of articles to this specification. The QAR is
authorised to witness any stage of manufacture, tests and to inspect documentation. The
QAR is authorised to reject any items not complying with the requirements of this
specification. In the event of a dispute arising regarding the interpretation of test results
the decision of the Project Engineer shall be final.


APPENDIX A: RELATED DOCUMENTS

AA SPEC 114005 Steel and FRP flooring, stairs, ladders and guardrails
Unless otherwise stated the latest issue of the following documents shall be deemed to form part
of this specification.
AA AFRS 7 : Working at Heights
AA BPG S03 : SIMM Guidelines for Plant Structure
AA BPG S06 : Guidelines for Layout and Inspection of Steel and FRP Floors, Stairs
and Guardrail
AA CPS 41A : Galvanised Iron and Steel Repair Procedure (Single Pack Zinc Rich)
AA CPS 000124 : New Work, Non-Immersion Two Coat Epoxy Coal Tar
AA SPEC 114001 : Design of Structural Steelwork
AA SPEC 114002 : Construction of Structural Steelwork
AA SPEC 164000 : Users Guide for Corrosion Protection: System Selection
AA STD 99 : Risk Management on Projects
AA STD 100 : Quality Requirements for Suppliers of Critical Equipment
AWS D1.1 : American Welding Society. Structural Welding Code Steel
BS 1449 : Steel plate and strip
BS 4592 : Specification for industrial flooring and stair treads
BS 5135 : Metal arc welding of carbon and carbon-manganese steels
ISO 834 : Fire resistance tests. Elements of building construction
ISO 1461 : Hot dip galvanised coatings on fabricated iron and steel articles
: Preparation of steel substrates before application of paints and related

ISO 8501
products. Visual assessment of surface cleanliness
ISO 9001 : Quality management systems
SANS 10400 : The Application of the National Building regulations
SANS 1137 : Hot applied bitumen for steel pipeline protection


APPENDIX B: RECORD OF AMENDMENTS
Issue 0 New document based on AAC Specification 114005 Rev 5 with a complete re-write
(G J Krige), September 2009


APPENDIX C: APPROPRIATE NATIONAL STANDARDS

COUNTRY
Code Letters Australia Canada South Africa Europe
GWS AS/NZS 3678 “Structural Steel”. SANS 1431 “Weldable structural steels”.
AS/NZS 3679 “Structural Steel”.
SLO AS/NZS 1170 “Minimum design SANS 10160 “The General Procedures and Loadings
Loads of Structures”. to be Adoped in the Design of Buildings
DLS SANS 10208-4 “Design of Structures for the Mining
Industry – Part 4: Shaft System Structures”.
SSC AS 4100 “Steel Structures”. SANS 2001 CS1 “Construction works Part CS1:
Structural steelwork”.
Standards
LSD AS 4100 “Steel Structures”. SANS 10162-1 “The use of structural steel. Part 1:
Hot Rolled Steelwork”.
AS/NZS 1554 “Structural Steel
Welding”.
STS ASTM 269 for tubing. ASTM 240 for plate and strip.
ISO Standard Australia Canada South Africa Europe
ISO 834 “Fire Resistance Tests – AS 1530 “Methods for Fire Tests SANS 10177 “Fire testing of materials, components
Elements of Building Construction”. on Building Materials”. and elements used in building”.
Description Australia Canada South Africa Europe
Graded high strength structural bolts Class 8.8 bolts
Graded standard strength structural bolts Class 4.8 bolts

Anglo Technical accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.

AA - SPEC - 114005 - Flooring, Stairs, Ladders & Handrails

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AA - SPEC - 114005 - Flooring, Stairs, Ladders & Handrails

Uploaded by

Copyright:

Available Formats

AA SPECIFICATION 114005

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

APPENDIX B: RECORD OF AMENDMENTS 44

APPENDIX C: APPROPRIATE NATIONAL STANDARDS 45

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 1 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

This document supersedes AAC Specification 114005 Rev 5

2.1 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 2 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

BEARER BAR : The load carrying component of walkway grating running

DLS : The appropriate national standard for limit states structural

FRP : Fibre Reinforced Polymer. The fibre used is usually glass

GWS : The appropriate national standard defining the chemical

LENGTH OF PANEL : Overall dimension of a grating panel measured parallel to the

LSD : The appropriate national standard for limit states design of

MINE ENGINEER : The Engineering Manager of the Purchaser, or a person

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 3 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

PITCH : The distance centre to centre of bearer bars or centre to

SLO : The appropriate national standard for structural loading

SSC : The appropriate national standard for structural steel

STAIR TREAD : A rectangular pattern bar grating with a non-slip nosing.

STS : The appropriate national standard for stainless steel

: A company that manufactures and supplies walkway grating,

: Member at right angles to the bearer bars to provide lateral

The following terms are defined in the General Conditions of Contract:

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 4 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

4.1 SAFETY AND RISK

4.1.2 Risk Assessment

The risk assessment shall consider at least the following:

3. Access and Escape

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 5 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

4.2 GENERAL REQUIREMENTS

4.2.2 Deviation from this Specification

4.2.3 Meaning and Precedence of Information

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 6 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

• The data sheets and/or drawings

4.3 REQUIREMENTS FOR DESIGN

4.3.2 Alternative Designs

All material shall be new.

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 7 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

2. General sections, tubes and plate

Stainless steel surface finishes shall not be less than a 2D finish.

AA SPEC 114002 – Appendix B (3CR12)

6. Resin Content and Ultraviolet Absorber

AA_SPEC_11400500.doc APPROVED 21 September 2009 Page 8 of 45

For information or comments on this document please contact AT R&A

STEEL AND FRP FLOORING, STAIRS, LADDERS ISSUE 0

All grating shall be manufactured with an ultraviolet absorber.

All grating shall be fire retardant, and shall be non-combustible at a temperature of

TABLE 4.1: SPECIFIC MATERIALS